Kona Kai Bill of Materials

The following list of materials is intended to be a general guide only. Before ordering any materials, the text and plans should be checked for possible options. All lumber listed as 1" stock is to be standard "lumberyard four-quarter" material which when finished may vary to somewhat less or slightly more than 3/4" in thickness, unless specified as NET. All widths are NET and all lengths allow for cutting to fit. Grouping lumber and purchasing random-random material to resaw to the required size will result in considerable savings. All lumber used should be first grade free from shakes and knots. Although oak (white oak), Sitka spruce, and mahogany (African, Honduras, or Phillipine-dark red varieties) are called out in the listing, lumber typical to the locale and of similar types and weights may be substituted. Long-leaf yellow pine is a good substitute for oak. All plywood (PW) is to be marine (MAR) or exterior (EXT) grade. The marine-type is preferable as the inner cores are solid and thus the panel has more structural integrity. Douglas-fir (DF) is satisfactory with the quality of the exposed faces of the veneer being designated by the letters "A" or "B". The "AA" grade panels are always preferable, however, "AB" grade is acceptable. All plywood should be a minimum of three plies. All fastenings should be bronze or hot dipped galvanized ferrous metal. Brass fastenings are not advised nor are the electroplated screws commonly sold in hardware stores. All screws are to be of the flat head type intended for wood. All nails are of the ring-type nail common to boat construction. Unless otherwise specified, all wood-to-wood joints are to be glued with a waterproof or highly water resistant glue such as plastic resin, resorcinol, epoxy, or other equivalent type used per the manufacturer's instructions regarding temperature, clamping requirements, curing time, and mixing method.
CHECK ALL SIZES TO THE WORK PRIOR TO CUTTING. Abbreviations used are: Mahog = mahogany; SP = Sitka spruce; DF = Douglas-fir; PW=plywood; Ext=exterior; MAR=marine.

ITEM MATERIAL NO.
PCS.
SIZE
LUMBER:
Frame members/deck beams* Mahog, Oak or SP 125 bd. ft. random-random five quarters (1-1/4") stock, some widths to 8"
Keel Mahog, Oak or SP 2
1
1"x6"x16' or optionally
2" x 6" x 16'*
Chine logs Mahog, Oak or SP 2 1-1/4" x 3" x 23'
Sheer clamps Mahog, Oak or SP 4 1" x 2" x 27'
Sheer clamps (inner lams) Mahog, Oak or SP 2 1" x 2" x 7'
Bottom battens Mahog, Oak or SP 2
2
2
1-1/4" x 3" x 20'
1-1/4" x 3" x 19'
1-1/4" x 3" x 17'-6"
Carlings Mahog, Oak or SP 2 1" x 6" x 16'
Cabin clamps Mahog, Oak or SP 2 1"net x 6" x 16'**
Deck battens Mahog, Oak or SP 2
2
2
1" x 2" x 5'
1" x 2" x 7'
1" x 2" x 8'-6"
Strongback Mahog, Oak or SP 1 1" x 2" x 8'
Transom uprights Mahog, Oak or DF 2 2" x 4" x 2'-6"*
Lift strakes Mahog, Oak or SP 2
4
1" x 2-1/2" x 18'
1" x 2" x 13'
Motor stringers (optional) Mahog, Oak or SP 2 2" x 6" x 8'*
Motor stringers blking (opt) Mahog, Oak or SP 1 2" x 2" x 8'*
PLYWOOD:
Bottom planking/butt blocks DF MAR AB or AA 2
4
1/2" x 4' x 12'***
1/4" x 4' x 12'***
Side planking/butt blocks DF MAR AB or AA 2
2
3/8" x 4' x 10'***
3/8" x 4' x 16'***
Floor timbers/gussets* DF Ext AB 1 3/8" x 4' x 8'
Stem, breasthook & floor timbers* DF Ext AB 1
1
3/4" x 4' x 8'
3/4" x 4' x 4'
Transom* DF Ext AB 1 3/4" x 4' x 8'
Decking/butt blocks DF Ext AB 2
1
3/8" x 4' x 10'***
3/8" x 4' x 8'
* Included in the Frame Kit
*Refers to standard lumberyard size stock in both width & thickness.
**See instructions for options for this member.
**4' x 8' sheets can be substituted for longer sheets in all cases. Adjust quantities accordingly.
FASTENINGS:
Screws: Flathead wood type, bronze or hot dipped galvanized
  • 3/4" #8 - 2 gross
  • 1" #8 - 7 gross
  • 1-1/4" #8 - 6 gross
  • 1-1/2" #8 - 4 gross
  • 2" #10 - 1 gross, 3 dozen
  • 3" #14 - 4 dozen
Nails: Ring type boat nails, bronze or Monel
  • 1" - 1 pound
  • 1-1/4" - 2 pounds
Carriage Bolts: Bronze or hot dipped galvanized complete with nuts and washers. Check all lengths to work.
  • 3/8" x 9" - 3 required - keel to stem
  • 5/16" x 9" - 5 required - keel to frames (using 1" x 4" bottom frame members)
  • 5/16" x 9" - 10 required - keel to frames (using sawn bottom frame members)
  • 5/16" x 3" - 8 required - deck beams to frames

Glue: Epoxy - 3 gallons



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